System and method for forming stacked materials

ABSTRACT

A system for forming stacked material includes a housing defining an interior space. The housing includes a bottom wall and a side wall coupled to the bottom wall. At least one tool is configured to shape the stacked material. The at least one tool is disposed within the interior space. A membrane extends at least partially over the bottom wall and is spaced a distance from the bottom wall. The membrane is configured to move towards the bottom wall. At least one intensifier mechanism is disposed in the interior space and is configured to induce a force against a portion of the stacked material and against the at least one tool as the membrane is moved towards the bottom wall.

BACKGROUND

The field of the disclosure relates generally to systems for formingstacked materials and, more particularly, to systems that includemembranes to facilitate forming stacked materials.

At least some known systems are used to form stacked materials intocomposite laminate components. The stacked materials include a pluralityof layers or plies of composite material that provide the compositelaminate component with improved engineering properties. For example,the stacked materials include layers of any of the following materials:prepregs, dry fabrics, carbon fabrics, tackified fabrics, release films,backing paper, vacuum films, liners, membranes, carbon fiber, glass,polymeric fibers such as polyimides and polyethylenes, ceramic matrixcomposites, silicon carbide, and alumina. In at least some systems, thestacked material is positioned adjacent to a tool and forced against thetool to shape the stacked material into the component shape. In somesystems, a membrane is used to facilitate shaping the stacked material.The membrane is extended over the stacked material and/or tool andpositioned in a controlled manner to cause the tool to shape the stackedmaterial.

In at least some known systems, the tool has complex geometries, such asoverhangs, undercuts, concave surfaces, and convex surfaces. However,the membrane bridges over these complex geometries and does not causethe stacked material to be adequately compacted. As a result, thestacked material is not properly formed adjacent to these complexgeometries. Therefore, additional processing, such as debulking, isrequired to properly form the stacked material into the desiredcomponent.

BRIEF DESCRIPTION

In one aspect, a system for forming stacked material is provided. Thesystem includes a housing defining an interior space. The housingincludes a bottom wall and a side wall coupled to the bottom wall. Atleast one tool is configured to shape the stacked material. The at leastone tool is disposed within the interior space. A membrane extends atleast partially over the bottom wall and is spaced a distance from thebottom wall. The membrane is configured to move towards the bottom wall.At least one intensifier mechanism is disposed in the interior space andis configured to induce a force against a portion of the stackedmaterial and against the at least one tool as the membrane is movedtowards the bottom wall.

In another aspect, a system for forming stacked material is provided.The system includes a housing defining an interior space. The housingincludes a bottom wall and a side wall coupled to the bottom wall. Atleast one tool is configured to shape the stacked material. The at leastone tool is disposed within the interior space. A membrane extends atleast partially over the bottom wall and is spaced a distance from thebottom wall. The membrane is configured to move towards the bottom wall.At least one insert is in the interior space.

In yet another aspect, a method of forming stacked material is provided.The method includes coupling the stacked material to a tool disposed inan interior space of a housing and moving a membrane towards the tool inthe interior space of the housing. The stacked material is shaped usingthe tool. The method further includes moving an intensifier mechanismsuch that the stacked material is compressed at predetermined locations.

DRAWINGS

These and other features, aspects, and advantages of the presentdisclosure will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a side view of an exemplary system for forming stackedmaterial including an intensifier mechanism;

FIG. 2 is a plan view of the intensifier mechanism of the system shownin FIG. 1;

FIG. 3 is a schematic diagram of a sequence for forming stackedmaterials using an exemplary system including an intensifier mechanismpositioned on the stacked materials;

FIG. 4 is a side view of an exemplary system for forming stackedmaterial;

FIG. 5 is a plan view of the system shown in FIG. 4;

FIG. 6 is a schematic diagram of a sequence for forming stacked materialusing a first configuration of the system shown in FIG. 4;

FIG. 7 is a schematic diagram of a sequence for forming stacked materialusing a second configuration of the system shown in FIG. 4;

FIG. 8 is a side view of the system shown in FIG. 4 including a firstset of inserts;

FIG. 9 is a side view of the system shown in FIG. 4 including a secondset of inserts;

FIG. 10 is a side view of the system shown in FIG. 4 including a thirdset of inserts;

FIG. 11 is a schematic diagram of forming a plurality of stackedmaterials onto a plurality of tools using the system shown in FIG. 4;

FIG. 12 is a plan view of a plurality of the systems shown in FIG. 4configured for forming a plurality of stacked materials onto a pluralityof tools;

FIG. 13 is schematic diagram of a sequence for forming stacked materialusing an exemplary system including intensifier mechanisms;

FIG. 14 is a schematic plan view of a sequence for forming stackedmaterial using the system shown in FIG. 13; and

FIG. 15 is a schematic diagram of a sequence for forming stackedmaterials using an exemplary system including intensifier mechanisms.

Unless otherwise indicated, the drawings provided herein are meant toillustrate features of embodiments of the disclosure. These features arebelieved to be applicable in a wide variety of systems including one ormore embodiments of the disclosure. As such, the drawings are not meantto include all conventional features known by those of ordinary skill inthe art to be required for the practice of the embodiments disclosedherein.

DETAILED DESCRIPTION

In the following specification and the claims, reference will be made toa number of terms, which shall be defined to have the followingmeanings.

The singular forms “a”, “an”, and “the” include plural references unlessthe context clearly dictates otherwise.

“Optional” or “optionally” means that the subsequently described eventor circumstance may or may not occur, and that the description includesinstances where the event occurs and instances where it does not.

Approximating language, as used herein throughout the specification andclaims, may be applied to modify any quantitative representation thatcould permissibly vary without resulting in a change in the basicfunction to which it is related. Accordingly, a value modified by a termor terms, such as “about,” “substantially,” and “approximately,” are notto be limited to the precise value specified. In at least someinstances, the approximating language may correspond to the precision ofan instrument for measuring the value. Here and throughout thespecification and claims, range limitations may be combined and/orinterchanged, such ranges are identified and include all the sub-rangescontained therein unless context or language indicates otherwise.

As used herein, the terms “processor” and “computer,” and related terms,e.g., “processing device,” “computing device,” and “controller” are notlimited to just those integrated circuits referred to in the art as acomputer, but broadly refers to a microcontroller, a microcomputer, aprogrammable logic controller (PLC), and application specific integratedcircuit, and other programmable circuits, and these terms are usedinterchangeably herein. In the embodiments described herein, memory mayinclude, but it not limited to, a computer-readable medium, such as arandom access memory (RAM), a computer-readable non-volatile medium,such as a flash memory. Alternatively, a floppy disk, a compactdisc—read only memory (CD-ROM), a magneto-optical disk (MOD), and/or adigital versatile disc (DVD) may also be used. Also, in the embodimentsdescribed herein, additional input channels may be, but are not limitedto, computer peripherals associated with an operator interface such as amouse and a keyboard. Alternatively, other computer peripherals may alsobe used that may include, for example, but not be limited to, a scanner.Furthermore, in the exemplary embodiment, additional output channels mayinclude, but not be limited to, an operator interface monitor.

Further, as used herein, the terms “software” and “firmware” areinterchangeable, and include any computer program storage in memory forexecution by personal computers, workstations, clients, and servers.

As used herein, the term “non-transitory computer-readable media” isintended to be representative of any tangible computer-based deviceimplemented in any method of technology for short-term and long-termstorage of information, such as, computer-readable instructions, datastructures, program modules and sub-modules, or other data in anydevice. Therefore, the methods described herein may be encoded asexecutable instructions embodied in a tangible, non-transitory,computer-readable medium, including, without limitation, a storagedevice and/or a memory device. Such instructions, when executed by aprocessor, cause the processor to perform at least a portion of themethods described herein. Moreover, as used herein, the term“non-transitory computer-readable media” includes all tangible,computer-readable media, including, without limitation, non-transitorycomputer storage devices, including without limitation, volatile andnon-volatile media, and removable and non-removable media such asfirmware, physical and virtual storage, CD-ROMS, DVDs, and any otherdigital source such as a network or the Internet, as well as yet to bedeveloped digital means, with the sole exception being transitory,propagating signal.

The systems described herein include a membrane to facilitate formingstacked material into a component. The system includes a housingdefining an interior space and a tool disposed in the interior space.The membrane is moved in the interior space towards the tool. In someembodiments, at least one insert is disposed in the interior space tocontrol movement of the membrane, reduce stretching of the membrane, andprovide a controlled movement of the membrane. In further embodiments,at least one intensifier mechanism is disposed in the interior space tofacilitate shaping the stacked material with the tool. The at least oneintensifier mechanism is configured to cause the tool to shape thecomponent into complex geometries. In some embodiments, the at least oneintensifier mechanism provides contact pressure between the stackedmaterial and the tool for increased compaction of the stacked material.

FIG. 1 is a side view of a system 10 for forming stacked material 12including an intensifier mechanism 14. FIG. 1 includes an X-axis, aY-axis, and a Z-axis for reference during the following description.FIG. 2 is a plan view of intensifier mechanism 14. System 10 includesintensifier mechanism 14, a housing 16, a tool 18, a membrane 20, andinserts 22. Housing 16 includes a bottom wall 24, a side wall 26 coupledto bottom wall 24, and a perforated plate 28 disposed on bottom wall 24.Housing 16 defines an interior space 30. In alternative embodiments,system 10 has any configuration that enables system 10 to operate asdescribed herein. For example, in some embodiments, tool 18, inserts 22,and/or housing 16 are integrally formed.

In the exemplary embodiment, stacked material 12 includes a plurality oflayers or plies of composite material. In alternative embodiments,stacked material 12 includes any layers that enable system 10 to operateas described herein. For example, in some embodiments, stacked material12 includes layers of any of the following materials, withoutlimitation: prepregs, dry fabrics, carbon fabrics, tackified fabrics,release films, backing paper, vacuum films, liners, membranes, carbonfiber, glass, polymeric fibers such as polyimides and polyethylenes,ceramic matrix composites, silicon carbide, and alumina.

During operation of system 10, a negative pressure is generated ininterior space 30 such that membrane 20 is drawn towards bottom wall 24.As membrane 20 moves towards bottom wall 24, membrane 20 contactsstacked material 12, tool 18, side wall 26, inserts 22, and intensifiermechanism 14. Intensifier mechanism 14 is positioned on stacked material12 adjacent tool 18 such that intensifier mechanism 14 induces a forcein stacked material 12 as membrane 20 moves towards bottom wall 24.Intensifier mechanism 14 is configured to move in directions along theX-axis, Z-axis, and Y-axis such that intensifier mechanism 14 contactsstacked material 12 at predetermined locations. In particular,intensifier mechanism 14 induces a force against portions of stackedmaterial 12 adjacent complex geometries on tool 18 to facilitate tool 18shaping stacked material 12.

In some embodiments, intensifier mechanism 14 is coupled to stackedmaterial 12 at fixed positions. In other embodiments, intensifiermechanism 14 is loosely positioned on stacked material 12. Inalternative embodiments, intensifier mechanism 14 is coupled to any ofhousing 16, tool 18, and membrane 20. For example, in some embodiments,intensifier mechanism 14 extends beyond stacked material 12 and couplesto tool 18. In further embodiments, at least a portion of intensifiermechanism 14 is fixed to tool 18. In still further embodiments,intensifier mechanism 14 is integral with tool 18. In some embodiments,intensifier mechanism 14 is removably coupled to tool 18.

In the exemplary embodiment, intensifier mechanism 14 is disposed ininterior space 30 and includes bodies 32 and support 34. Each body 32has a shape that corresponds to a desired shape of a component formedfrom stacked material 12 and engages a portion of tool 18. Support 34extends between bodies 32 and is coupled to bodies 32 such that bodies32 are movable in relation to housing 16. In particular, bodies 32 andsupport 34 are movably coupled together such that at least a portion ofbodies 32 pivots about support 34. Accordingly, support 34 forms ahinge. In some embodiments, each support 34 and/or bodies 32 includesany number of segments, including one, that enable system 10 to operateas described herein. In the exemplary embodiment, support 34 includestwo segments coupled to bodies 32 at positions that facilitate bodies 32inducing forces in stacked material 12 at precise locations. In furtherembodiments, support 34 includes a plurality of segments extendingbetween the same bodies 32. In some embodiments, support 34 extends thefull length of intensifier mechanism 14. In alternative embodiments,intensifier mechanism 14 has any configuration that enables system 10 tooperate as described herein. For example, in some embodiments,intensifier mechanism 14 is formed as a single integrated component. Infurther embodiments, intensifier mechanism 14 includes at least one body32 embedded in support 34. In still further embodiments, intensifiermechanism 14 includes at least one body 32 and support 34 is omitted.

Also, in the exemplary embodiment, intensifier mechanism 14 is made frommaterials that facilitate the positioning of intensifier mechanism 14during operation of system 10. For example, support 34 is made from amaterial that is flexible to enable bodies 32 to move and has somerigidity to maintain proper positioning of intensifier mechanism 14 inrelation to stacked material 12. Bodies 32 are substantially rigid toretain shape during positioning. Moreover, intensifier mechanism 14 ismade from materials that withstand relatively high temperatures. Forexample, support 34 and bodies 32 remain sufficiently rigid to retaintheir shape when system 10 is heated. In alternative embodiments,intensifier mechanism 14 is made of any materials that enable system 10to operate as described herein. For example, in some embodiments,intensifier mechanism 14 is made from materials that are compatible withstacked material 12, e.g., materials that do not contaminate stackedmaterial 12 when intensifier mechanism 14 directly contacts stackedmaterial 12. In further embodiments, bodies 32 are made from semi-rigidmaterials. For example, in some embodiments, bodies 32 include any ofthe following materials: silicone, rubber, semi-rigid plastic, andcombinations thereof.

In addition, in the exemplary embodiment, system 10 further includes aliner 36 extending between intensifier mechanism 14 and stacked material12. Liner 36 inhibits intensifier mechanism 14 and membrane 20contacting stacked material 12. Liner 36 is coupled to side wall 26 andmaintained in tension to facilitate forming stacked material 12. Inparticular, liner 36 reduces indentations and irregularities in stackedmaterial 12 when intensifier mechanism 14 induces a force in stackedmaterial 12. Moreover, liner 36 facilitates removal of formed stackedmaterial 12 from system 10 and reduces deterioration and contaminationof system 10. In some embodiments, liner 36 is a release film. Infurther embodiments, liner 36 is a polypropylene material. Inalternative embodiments, system 10 includes any liner 36 that enablessystem 10 to operate as described herein. For example, in someembodiments, intensifier mechanism 14 is semi-rigid and liner 36 ispositioned above intensifier mechanism 14 and stacked material 12. Infurther embodiments, liner 36 is coupled to any of stacked material 12,intensifier mechanism 14, and membrane 20 that enable system 10 tooperate as described herein.

FIG. 3 is a schematic diagram of a sequence for forming stacked material400 using a system 402 including an intensifier mechanism 404 positionedon stacked materials 400. FIG. 3 includes an X-axis, a Y-axis, and aZ-axis for reference during the following description. System 402includes intensifier mechanisms 404, a housing 406, a tool 408, amembrane 410, a liner 411, and inserts 412. Housing 406 defines aninterior space 414 and includes a bottom wall 416, a side wall 418coupled to bottom wall 416, and a perforated plate 420 disposed onbottom wall 416.

Intensifier mechanism 404 is positioned on stacked material 400 adjacenttool 408 such that intensifier mechanism 404 induces a force in stackedmaterial 400 as membrane 410 moves towards bottom wall 416. In someembodiments, liner 411 is positioned between intensifier mechanism 404and stacked material 400. In the exemplary embodiment, intensifiermechanism 404 includes a plurality of bodies 422 and a support 424coupling bodies 422 together. In particular, intensifier mechanism 404includes two bodies 422 that each correspond to a shape of a portion oftool 408. Support 424 is flexible and facilitates positioningintensifier mechanism 404 as membrane 410 moves towards bottom wall 416.In particular, intensifier mechanism 404 is positioned adjacent tool 408such that bodies 422 induce forces in stacked material 400 and theportions of tool 408 with shapes corresponding to intensifier mechanism404. In alternative embodiments, intensifier mechanism 404 has anyconfiguration that enables system 402 to operate as described herein.For example, in some embodiments, intensifier mechanism 404 includes onebody 422. In further embodiments, intensifier mechanism 404 includes aplurality of bodies 422 that are not coupled together by support 424.

FIG. 4 is a side view of a system 100 for forming stacked material 102.FIG. 4 includes an X-axis, a Y-axis, and a Z-axis for reference duringthe following description. FIG. 5 is a plan view of system 100. FIG. 5includes an X-axis, a Y-axis, and a Z-axis for reference during thefollowing description. System 100 includes a housing 104, a tool 106, amembrane 108, a temperature control unit 110, a controller 112, and avacuum source 114. Housing 104 includes a bottom wall 116, a top wall118, and a side wall 120 extending between bottom wall 116 and top wall118. Bottom wall 116, top wall 118, and side wall 120 define an interiorspace 122. In the exemplary embodiment, side wall 120 is coupled tobottom wall 116 and top wall 118 such that side wall 120 issubstantially orthogonal to bottom wall 116 and top wall 118. Moreover,bottom wall 116 is substantially rectangular and side wall 120 extendsaround the perimeter of bottom wall 116. Accordingly, housing 104 issubstantially box-shaped. In some embodiments, at least a portion of atleast one of bottom wall 116, top wall 118, and side wall 120 ispositionable between open and closed positions to facilitate access tointerior space 122. In further embodiments, housing 104 includes anaccess panel (not shown). In alternative embodiments, housing 104 hasany configuration that enables system 100 to operate as describedherein. For example, in some embodiments, top wall 118 is omitted. Infurther embodiments, at least one of bottom wall 116, top wall 118, andside wall 120 is angled to facilitate controlling the movement ofmembrane 108.

In the exemplary embodiment, bottom wall 116 includes a perforated plate124. Perforated plate 124 facilitates airflow 125 between interior space122 and the exterior of housing 104. In particular, perforated plate 124defines a plurality of openings 126 for airflow 125 through perforatedplate 124. Vacuum source 114 is coupled in flow communication withopenings 126 to control the airflow 125 through perforated plate 124. Inaddition, in some embodiments, any components of system 100, such astool 106, include openings 126 to facilitate airflow 125 through housing104. Openings 126 are evenly spaced throughout perforated plate 124 suchthat airflow 125 through perforated plate 124 is substantially uniform.Other than openings 126, housing 104 is substantially airtight such thatthe environment of interior space 122 is controlled during operation ofsystem 100. In alternative embodiments, housing 104 includes anyopenings 126 that enable system 100 to operate as described herein. Infurther embodiments, openings 126 are omitted.

Also, in the exemplary embodiment, tool 106 is disposed in interiorspace 122 and configured to support stacked material 102. Stackedmaterial 102 is coupled to tool 106 such that stacked material 102 ismaintained at a desired tension. Tool 106 is coupled to bottom wall 116and spaced from side wall 120 along the X-axis and the Y-axis. Tool 106is configured to shape stacked material 102 into a component having adesired shape. For example, in some embodiments, tool 106 shapes stackedmaterial into any of the following, without limitation: ageometrically-shaped structure, a component including undercuts, anairfoil, a turbine component, a shell, a stiffening element, a skin, aguide vane, an attachments clip, an L-frame, a Z-frame, an Omega-frame,a U-frame, and a shaped frame. In alternative embodiments, tool 106 hasany configuration that enables system 100 to operate as describedherein.

In addition, in the exemplary embodiment, membrane 108 extends overbottom wall 116. In particular, membrane 108 is coupled to side wall 120a distance 128 above bottom wall 116 in the Z-direction. Distance 128 isgreater than a height 121 of tool 106. In alternative embodiments,distance 128 is any measurement that enables system 100 to operate asdescribed herein. In the exemplary embodiment, membrane 108 isconfigured such that at least a portion of membrane 108 moves towardsbottom wall 116 during operation of system 100. Membrane 108 is aflexible sheet structure and is at least partially elastic. At leastinitially, membrane 108 is spaced a minimum distance 129 from bottomwall 116. As membrane 108 moves toward bottom wall 116, membrane 108stretches. Membrane 108 is coupled to side wall 120 such that membrane108 is maintained in tension as membrane 108 moves toward bottom wall116. The tension facilitates membrane 108 moving in a controlled mannerand contacting objects evenly. In alternative embodiments, membrane 108has any configuration that enables system 100 to operate as describedherein. For example, in some embodiments, membrane 108 includes abladder and/or diaphragm structure. Membrane 108 is formed from anymaterials that enable system 100 to operate as described herein. Forexample, in some embodiments, membrane 108 is formed from any of thefollowing stretchable materials, without limitation: silicone, rubber,release liners, vacuum liners, and combinations thereof. In theexemplary embodiment, membrane 108 is elastic such that membrane 108 isrepeatedly stretched. In alternative embodiments, membrane 108 isconfigured for only a single use.

Moreover, in the exemplary embodiment, inserts 130 are disposed ininterior space 122. Inserts 130 are removably coupled to bottom wall 116to facilitate repositioning inserts 130. Inserts 130 are positionedbetween side wall 120 and tool 106. In the exemplary embodiment, inserts130 are inclined planes positioned adjacent side walls 120. Inserts 130extend substantially the entire span of side walls 120 along the Y-axis.In alternative embodiments, inserts 130 have any configuration thatenables system 100 to operate as described herein.

FIG. 6 is a schematic diagram of a sequence for forming stacked material102 using system 100 in a first configuration. In operation of system100, vacuum source 114 generates a negative pressure, i.e., a vacuum, ininterior space 122 to facilitate membrane 108 moving towards bottom wall116. Controller 112 (shown in FIG. 4) controls vacuum source 114 toregulate the pressure of interior space 122 and thereby control movementof membrane 108. In addition, after stacked material 102 is formed,vacuum source 114 increases pressure in interior space 122 to causemembrane 108 to move away from bottom wall 116. In alternativeembodiments, membrane 108 is configured to move in any manner thatenables system 100 to operate as described herein. For example, in someembodiments, the pressure above membrane 108 is increased to forcemembrane 108 into interior space 122. In further embodiments, a biasingmember is coupled to membrane 108 to facilitate controlled movement ofmembrane 108.

As membrane 108 is drawn towards bottom wall 116, membrane 108 contactsstacked material 102, tool 106, side wall 120, bottom wall 116, andinserts 130. In alternative embodiments, membrane 108 contacts anycomponents of system 100 that enable system 100 to operate as describedherein. In the exemplary embodiment, stacked material 102 includes aliner 132 for membrane 108 to contact. Liner 132 inhibits membrane 108contacting stacked material 102. In some embodiments, liner 132 isremoved after formation of stacked material 102. In alternativeembodiments, liner 132 is omitted. In further embodiments, liner 132 isincluded in any components of system 100, including membrane 108, thatenables system 100 to operate as described herein.

In the exemplary embodiment, membrane 108 stretches as membrane 108moves towards bottom wall 116. In addition, membrane stretches asmembrane 108 contacts stacked material 102, tool 106, side wall 120,and/or bottom wall 116. Inserts 130 at least partially support membrane108 to reduce the amount membrane 108 stretches during operation ofsystem 100. In addition, inserts 130 facilitate membrane 108 moving in acontrolled manner towards bottom wall 116. As a result, inserts 130facilitate system 100 forming stacked materials 102 with increasedoperating efficiency.

Also, in the exemplary embodiment, temperature control unit 110maintains interior space 122 and stacked material 102 at a desiredtemperature during operation of system 100. In some embodiments,temperature control unit 110 includes a heating and/or cooling source toincrease and/or decrease the temperature of interior space 122 and,thereby, control the pliability of stacked material 102. The heatingand/or cooling source is disposed inside of housing 104, disposedoutside of housing 104, and/or integrated into housing 104. Inalternative embodiments, tool 106 is maintained at a desired temperatureby temperature control unit 110 and a heating and/or cooling source. Infurther embodiments, temperature control unit 110 includes a temperaturecontrolled enclosure, such as an oven or a cooler, and housing 104 ispositioned at least partially within the temperature controlledenclosure. In alternative embodiments, temperature control unit 110 hasany configuration that enables system 100 to operate as describedherein.

Moreover, in the exemplary embodiment, controller 112 controls vacuumsource 114 to control movement of membrane 108. In some embodiments,controller 112 controls any components of system 100 to facilitate theautomation of the forming process. For example, in some embodiments,controller 112 controls a positioning member (not shown) to positionstacked material 102 on tool 106. In further embodiments, controller 112controls the movement and positioning of inserts 130. In addition, insome embodiments, controller 112 controls the positioning of intensifiermechanism 14, intensifier mechanisms 204 (shown in FIGS. 13-14 anddescribed further below), and intensifier mechanisms 304 (shown in FIG.15 and described further below), and intensifier mechanisms 404 (shownin FIG. 16 and described further below). In alternative embodiments,controller 112 has any configuration that enables system 100 to operateas described herein.

FIG. 7 is a schematic diagram of a sequence for forming stacked material102 using system 100 in a second configuration. FIG. 7 includes anX-axis and a Z-axis for reference during the following description.Perforated plate 124 is positioned at an angle 134 in relation to sidewall 120. Positioning perforated plate 124 at angle 134 facilitatesstacked material 102 contacting membrane 108 and tool 106. In addition,perforated plate 124 is at least partially raised a distance in theZ-direction. As a result, membrane 108 undergoes less stretching duringoperation of system 100 than if perforated plate 124 was located agreater distance from the starting position of membrane 108. Inserts 130are shaped to accommodate the position of perforated plate 124. Inparticular, insert 130 adjacent the elevated portion of perforated plate124 has a decreased height in the Z-direction in comparison to insert130 adjacent the lower portion of perforated plate 124 such that thetops of insert 130 are approximately even with each other. As a result,inserts 130 contact membrane 108 at substantially the same point alongthe Z-axis during movement of membrane 108.

FIGS. 8-10 are side views of system 100 including a plurality of inserts131. Inserts 131 have any shapes that enable system 100 to operate asdescribed herein. For example, in some embodiments, inserts 131 have atleast one of a cylindrical shape, a prism shape, and combinationsthereof. In the exemplary embodiment, some inserts 131 are adjacent sidewall 120 and some inserts 131 are adjacent tool 106. In addition,inserts 131 are stacked on top of each other to form structures havingdifferent heights and shapes. Inserts 131 include flexible and/or rigidmaterials. Inserts 131 that are flexible deform at least slightly asmembrane 108 contacts inserts 131. Inserts 131 that are rigid maintainsubstantially the same shape as membrane 108 contacts inserts 131.Accordingly, the rigidity and flexibility of inserts 131 is adjusted tocontrol the movement of membrane 108 and provide support for membrane108. In alternative embodiments, inserts 131 have any configurationsthat enable system 100 to operate as described herein.

For example, FIG. 8 is a side view of system 100 including inserts 131having rectangular prism shapes. Some inserts 131 are stacked verticallyand some inserts 131 are aligned horizontally. FIG. 9 is a side view ofsystem 100 including inserts 141 having a triangular prism shape. FIG.10 is a side view of system 100 including inserts 143 having arectangular prism shape.

With reference to FIGS. 9-10, system 100 includes inserts 136 thatextend through interior space 122 and function as dividers to divideinterior space 122 into a plurality of forming zones 138. A plurality oftools 106 are disposed in interior space 122 to facilitate forming aplurality of stacked materials 102. In particular, one forming tool 106and one stacked material 102 are disposed in each forming zone 138.Insert 136 extends between tools 106 to define forming zones 138. Insome embodiments, insert 136 has a height 140 greater than a height 142of tool 106 such that membrane 108 contacts insert 136 prior tocontacting stacked material 102 supported on tool 106. In someembodiments, insert 136 is formed by a single insert 130 having, forexample, a substantially flat plate shape. In other embodiments, aplurality of inserts 130 are stacked to form insert 136. In alternativeembodiments, insert 136 has any configuration that enables system 100 tooperate as described herein. For example, in some embodiments insert 136is permanently affixed to or integral with housing 104.

FIG. 11 is a schematic diagram of forming a plurality of stackedmaterials 102 using system 100. In one embodiment, insert 136 ispositioned between tools 106 to separate forming zones 138. In anotherembodiment, insert 136 is omitted. In further embodiments, insert 136hermetically separates forming zones 138 such that forming zones 138form separate controlled environments. Accordingly, the movement ofmembrane 108 in each forming zone 138 is separately controlled.Moreover, in some embodiments, forming zones 138 each include separatemembranes 108. In alternative embodiments, forming zones 138 have anyconfiguration that enables system 100 to operate as described herein.

FIG. 12 is a plan view of a plurality of systems 100 configured forforming a plurality of stacked materials 102. FIG. 12 includes anX-axis, a Y-axis, and a Z-axis for reference during the followingdescription. Systems 100 include different number of tools 106 indifferent numbers of forming zones 138. Some forming zones 138 areseparated by insert 136 and some forming zones 138 are not separated byinsert 136. Forming zones 138, inserts 136, and tools 106 are spacedalong the X-axis and the Y-axis. Each forming zone 138 includes at leastone tool 106. In alternative embodiments, forming zones 138 have anyconfiguration that enables system 100 to operate as described herein. Inthe exemplary embodiment, inserts 136 are substantially linear andpositioned orthogonal or parallel to the X-axis and the Y-axis. Inalternative embodiments, inserts 136 are non-linear. For example, insome embodiments, inserts 136 include any of the following withoutlimitation: curves, S-shaped portions, C-shaped portions, and L-shapedportions. In further embodiments, inserts 136 are positioned at anyangles in respect to the X-axis, a Y-axis, and a Z-axis that enablesystem 100 to operate as described herein.

FIG. 13 is a schematic diagram of a sequence of forming stacked material200 using a system 202 including intensifier mechanisms 204. FIG. 13includes an X-axis, a Y-axis, and a Z-axis for reference during thefollowing description. FIG. 14 is a schematic plan view of a sequence offorming stacked materials using system 202. FIG. 14 includes an X-axis,a Y-axis, and a Z-axis for reference during the following description.System 202 includes intensifier mechanisms 204, a housing 206, a tool208, a membrane 210, and inserts 212. Housing 206 includes a bottom wall214, a side wall 216 coupled to bottom wall 214, and a perforated plate218 disposed on bottom wall 214. Housing 206 defines an interior space220. During operation of system 202, a negative pressure is generated ininterior space 220 such that membrane 210 is drawn towards bottom wall214. As membrane 210 moves towards bottom wall 214, membrane 210contacts stacked material 200, tool 208, side wall 216, inserts 212, andintensifier mechanisms 204. When membrane 210 contacts intensifiermechanisms 204, intensifier mechanisms 204 move towards tool 208 andstacked material 200. Intensifier mechanisms 204 are configured to pressstacked material 200 against tool 208 such that stacked material 200 iscompacted. Intensifier mechanisms 204 are configured to extend and movein directions along the X-axis, Z-axis, and Y-axis such that intensifiermechanisms contact stacked material 200 at predetermined locations. Inparticular, intensifier mechanisms 204 induce a force against a portionof stacked material 200 adjacent complex geometries on tool 208 tofacilitate tool 208 shaping stacked material 200. Moreover, intensifiermechanisms 204 limit the amount of stretching of membrane 210.

Intensifier mechanisms 204 are disposed in interior space 220 andinclude a body 222 and a support 224. Support 224 is coupled to housing206 and body 222 such that body 222 is movable in relation to housing206. In particular, body 222 and support 224 are movably coupledtogether such that body moves along support 224. Support 224 includesrails 226 coupled to opposed portions of side wall 216. In alternativeembodiments, support 224 is coupled to any components of system 202 thatenable system 202 to operate as described herein. In the exemplaryembodiment, rails 226 are angled along side wall 216 such that body 222moves in directions along both the X-axis and the Z-axis. Body 222extends between rails 226 and has a shape that corresponds to a desiredshape of a component formed from stacked material 12 and engages aportion of tool 208. In alternative embodiments, intensifier mechanisms204 have any configuration that enables system 202 to operate asdescribed herein. For example, in some embodiments, intensifiermechanisms 204 are positioned on the side of membrane 210 exterior tointerior space 220 and compress membrane 210 and stacked material 200against tool 208. In further embodiments, intensifier mechanisms 204 areintegrated into and/or coupled to tool 208 and/or membrane 210.

In the exemplary embodiment, support 224 includes two rails 226 that areparallel. In some embodiments, support 224 includes any number of rails226, including one, that enable system 202 to operate as describedherein. In further embodiments, support 224 includes a plurality ofrails 226 and at least two rails of the plurality of rails 226 are notparallel. For example, in some embodiments, body 222 has an asymmetricshape such that body 222 extends between rails 226 that are notparallel.

Also, in the exemplary embodiment, intensifier mechanisms 204 arepositionable between multiple positions. In particular, intensifiermechanisms 204 move from a position spaced from tool 106 and stackedmaterial 200 to a position where intensifier mechanisms contact stackedmaterial 200 to press stacked material 200 against tool 208 at a desiredpressure. For example, in a first position, intensifier mechanisms 204do not exert a substantial force against stacked material 200. In asecond position, intensifier mechanisms 204 cause compaction of stackedmaterial 200. In alternative embodiments, intensifier mechanisms 204 arepositionable in any positions that enable system 202 to operate asdescribed herein. In some embodiments, intensifier mechanisms 204include biasing mechanisms, such as springs, to facilitate movement ofintensifier mechanisms 204.

FIG. 15 is a schematic diagram of a sequence of forming stacked material300 using a system 302 including intensifier mechanisms 304. FIG. 15includes an X-axis, a Y-axis, and a Z-axis for reference during thefollowing description. System 302 includes intensifier mechanisms 304, ahousing 306, a tool 308, a membrane 310, and inserts 312. Housing 306defines an interior space 314 and includes a bottom wall 316, a sidewall 318 coupled to bottom wall 316, and a perforated plate 320 disposedon bottom wall 316.

Intensifier mechanisms 304 include bodies 322 and a support 324. Support324 is movably coupled to bottom wall 316 at a joint 326 such thatintensifier mechanism 304 rotates about joint 326. In addition, support324 is rotatably coupled to bodies 322 to facilitate bodies 322 rotatingto contact stacked material 300 on tool 308. Intensifier mechanism 304is configured such that body 222 moves in directions along both theX-axis and the Z-axis. Bodies 322 are shaped to correspond to a shape oftool 308. In some embodiments, intensifier mechanisms 304 and tool 308are shaped to form corresponding male and female components. Inalternative embodiments, intensifier mechanisms 304 have anyconfiguration that enables system 100 to operate as described herein.

In reference to FIGS. 4-6 and 13, a method of forming stacked materials102 includes coupling stacked material 102 to tool 106 disposed ininterior space 122 of housing 104. Vacuum source 114 generates a vacuumpressure in interior space 122 such that membrane 108 moves towardbottom wall 116. Membrane 108 contacts stacked material 102 and forcesstacked material 102 against tool 106 such that tool 106 shapes stackedmaterial 102. Temperature control unit 110 maintains stacked material102 at a desired temperature. For example, in some embodiments,temperature control unit 110 increases the temperature of stackedmaterial 102 to facilitate tool 106 shaping stacked material 102. Infurther embodiments, the temperature of membrane 108 is increased. Insome embodiments, membrane 108 contacts intensifier mechanism 304 tocause intensifier mechanism 304 to move. Intensifier mechanism 304 ispositioned to cause stacked material 102 to contact tool 106 atpredetermined locations. In further embodiments, intensifier mechanism304 contacts stacked materials 102 with a predetermined force. In someembodiments, membrane 108 contacts insert 130 as membrane moves towardbottom wall 116. Insert 130 supports membrane 108 and controls themovement of membrane 108.

The above described systems include a membrane to facilitate formingstacked material into a component. The system includes a housingdefining an interior space and a tool disposed in the interior space.The membrane is moved in the interior space towards the tool. In someembodiments, at least one insert is disposed in the interior space tocontrol movement of the membrane and reduce stretching of the membrane.In further embodiments, at least one intensifier mechanism is disposedin the interior space to facilitate shaping the stacked material withthe tool. The at least one intensifier mechanism is configured to causethe tool to shape the component into complex geometries. In someembodiments, the at least one intensifier mechanism provides contactpressure between the stacked material and the tool for increasedcompaction of the stacked material.

An exemplary technical effect of the methods, systems, and apparatusdescribed herein includes at least one of: (a) increasing operatingefficiency of systems for forming stacked materials; (b) enablingcomponents formed from stacked materials to have complex geometries; (c)reducing the cost of forming stacked materials; (d) increasing thereliability of systems for forming stacked materials; (e) enablingstacked materials to be debulked during formation; (f) reducing cost andtime required to form stacked materials; and (g) simplifying the formingprocess for stacked materials.

Some embodiments involve the use of one or more electronic or computingdevices. Such devices typically include a processor or controller, suchas a general purpose central processing unit (CPU), a graphicsprocessing unit (GPU), a microcontroller, a field programmable gatearray (FPGA), a reduced instruction set computer (RISC) processor, anapplication specific integrated circuit (ASIC), a programmable logiccircuit (PLC), and/or any other circuit or processor capable ofexecuting the functions described herein. In some embodiments, themethods described herein are encoded as executable instructions embodiedin a computer readable medium, including, without limitation, a storagedevice, and/or a memory device. Such instructions, when executed by aprocessor, cause the processor to perform at least a portion of themethods described herein. The above examples are exemplary only, andthus are not intended to limit in any way the definition and/or meaningof the term processor.

Exemplary embodiments of systems for forming stacked materials aredescribed above in detail. The systems, and methods of operating andmanufacturing such systems are not limited to the specific embodimentsdescribed herein, but rather, components of systems and/or steps of themethods may be utilized independently and separately from othercomponents and/or steps described herein. For example, the methods mayalso be used in combination with other forming systems, and are notlimited to practice with only systems, and methods as described herein.Rather, the exemplary embodiment can be implemented and utilized inconnection with many other applications for forming materials.

Although specific features of various embodiments of the disclosure maybe shown in some drawings and not in others, this is for convenienceonly. In accordance with the principles of the disclosure, any featureof a drawing may be referenced and/or claimed in combination with anyfeature of any other drawing.

This written description uses examples to disclose the embodiments,including the best mode, and also to enable any person skilled in theart to practice the embodiments, including making and using any devicesor systems and performing any incorporated methods. The patentable scopeof the disclosure is defined by the claims, and may include otherexamples that occur to those skilled in the art. Such other examples areintended to be within the scope of the claims if they have structuralelements that do not differ from the literal language of the claims, orif they include equivalent structural elements with insubstantialdifferences from the literal language of the claims.

What is claimed is:
 1. A system for forming stacked material, saidsystem comprising: a housing defining an interior space and comprising abottom wall and a side wall coupled to said bottom wall; at least onetool configured to shape the stacked material, said at least one tooldisposed within said interior space; a membrane extending at leastpartially over said bottom wall and spaced a distance from said bottomwall, said membrane configured to move towards said bottom wall; and atleast one intensifier mechanism disposed in said interior space andconfigured to induce a force against a portion of the stacked materialand against said at least one tool as said membrane is moved towardssaid bottom wall.
 2. The system in accordance with claim 1, wherein saidmembrane contacts said at least one intensifier mechanism to move saidat least one intensifier mechanism towards said at least one tool. 3.The system in accordance with claim 1 further comprising a linerextending adjacent the stacked material.
 4. The system in accordancewith claim 1, wherein said at least one tool is configured to supportthe stacked material, and said at least one intensifier mechanism isconfigured to move between a first position spaced from said at leastone tool and a second position where said at least one intensifiermechanism induces a force against a portion of the stacked material andagainst said at least one tool.
 5. The system in accordance with claim1, wherein said at least one intensifier mechanism comprises at leastone support and at least one body movably coupled to said support. 6.The system in accordance with claim 5, wherein said at least one bodyhas a shape that corresponds to a desired shape of a component formedfrom the stacked material.
 7. The system in accordance with claim 5,wherein said at least one body is configured to pivot about said atleast one support.
 8. The system in accordance with claim 1 furthercomprising a temperature control unit configured to maintain the stackedmaterial at a desired temperature to facilitate shaping the stackedmaterial using the tool.
 9. A system for forming stacked material, saidsystem comprising: a housing defining an interior space and comprising abottom wall and a side wall coupled to said bottom wall; at least onetool configured to shape the stacked material, said at least one tooldisposed within said interior space; a membrane extending at leastpartially over said bottom wall and spaced a first distance from saidbottom wall, said membrane configured to move towards said bottom wall;and at least one insert in said interior space.
 10. The system inaccordance with claim 9, wherein said at least one tool comprises aplurality of tools, said at least one insert dividing said interiorspace into a plurality of forming zones, said at least one insertextending at least partially between a first tool and a second tool ofsaid plurality of tools.
 11. The system in accordance with claim 9,wherein said at least one insert is removably coupled to said bottomwall.
 12. The system in accordance with claim 9, wherein said at leastone tool is disposed on said bottom wall, said at least one insertextending at least partially between said at least one tool and saidside wall.
 13. The system in accordance with claim 9, wherein said atleast one tool extends a height above said bottom wall, said membranecoupled to said side wall a second distance above said bottom wallgreater than the height of said at least one tool.
 14. The system inaccordance with claim 9, wherein said at least one insert is configuredto at least partially contact said membrane as said membrane is loweredtowards said bottom wall.
 15. A method of forming stacked material, saidmethod comprising: coupling the stacked material to a tool disposed inan interior space of a housing; moving a membrane towards the tool inthe interior space of the housing; shaping the stacked material usingthe tool; and moving an intensifier mechanism such that the stackedmaterial is compressed at predetermined locations.
 16. The method inaccordance with claim 15, wherein moving the intensifier mechanismcomprises moving the intensifier mechanism to a position where theintensifier mechanism contacts the stacked material with a predeterminedforce.
 17. The method in accordance with claim 15, wherein moving theintensifier mechanism comprises contacting the intensifier mechanismwith the membrane.
 18. The method in accordance with claim 15 furthercomprising contacting an insert with the membrane, the insert in theinterior space.
 19. The method in accordance with claim 15, whereinshaping the stacked material comprises shaping a plurality of stackedmaterials using a plurality of tools.
 20. The method in accordance withclaim 15 further comprising: generating a vacuum force in the interiorspace to facilitate drawing the membrane towards the tool; andmaintaining the stacked material at a desired temperature to facilitateshaping the stacked material using the tool.